Cordless drywall sander

ABSTRACT

One embodiment of an adjustable dry wall sander comprises a handle ( 40 ), a pole ( 11 ), a portable, rechargeable electric power source ( 50 ) powering a vibrating eccentrically weighted electric motor ( 21 ) and interchangeable sanding head ( 30 ).

FEDERALLY SPONSORED RESEARCH

Not Applicable

SEQUENCE LISTING OR PROGRAM

Not Applicable

BACKGROUND

1. Field of Invention

The present invention generally relates to the field of power tools, and more particularly to a device for sanding drywall.

2. Prior Art

Drywall panels assembled to cover walls are bonded together using a process by which tape applied to any holes and seams and then covered in joint compound embedding said tape and forming a unified sheet upon drying. Once dry any excess compound is then sanded smooth. Commonly hand sanding using poles or blocks is used. This method requires great stamina, and strength especially when working on large ceilings.

On larger jobs heavy, corded, electrically powered rotational sanders are employed. These produce large amounts of dust due to their rotational disks and their high torque. These machines also require a great amount of strength and stamina as the machines are heavy and restricted by electrical cords. These electrical cords become a tripping hazard on many job sites. Additionally rotational drywall sanders have difficulties with the corner where a wall and ceiling meet and this area needs to be hand sanded. Rotary sander operators must frequently change positions as these sanders do not have the ability to have fully pivoting sanding heads.

It would be desirable to provide a sander capable of being lightweight, which creates less dust than current motorized drywall sanders, and is free from cumbersome and potentially dangerous electrical cords.

SUMMARY

In accordance with one embodiment an adjustable dry wall sander comprises a handle, a pole, a portable, rechargeable electric power source powering a vibrating eccentrically weighted electric motor and interchangeable sanding head.

DRAWINGS

Figures

FIG. 1 shows the overall tool and its components without cutaways.

FIG. 2 shows a cutaway of the motor enclosure and sanding head attachment.

DRAWINGS Reference Numerals

10 pole 11 shaft of pole 20 motor enclosure 21 electric motor 22 bolts 23 electric wires 24 eccentrically mounted weight 25 mounting block 30 sanding head 32 sanding head screw mount 40 handle 42 actuator switch 50 rechargeable electric power source

DETAILED DESCRIPTION FIGS. 1 and 2—Preferred Embodiment

One embodiment of the tool is illustrated in FIG. 1 (side view) and FIG. 2 (cutaway/detail view). The rechargeable electric power source connects to the handle the electric motor 21 is mounted externally to the shaft of the pole 11 using bolts 22 threaded through the mounting block 25. The mounting block 25 is attached to the electric motor 21 via a spot welded joint. Connected to electric motor 21 is eccentrically mounted weight 24 composed of lead or other some other similarly heavy metal and connected via press fitting. Covering electric motor assembly 21 is the two halves of plastic motor enclosure 20 attached to pole 11 via screws. Sanding head 30 is connected to pole 11 at sanding head screw mount 32 via a screw end on pole 11 fitting into sanding head screw mount 32 on sanding head 30. Electric motor 21 is powered using electric wires 23 which are run through pole 11 to handle 40 with one wire connected directly to the rechargeable electric power source and the other to actuator switch 42.

Operation

The manner of using the cordless drywall sander to sand drywall or gypsum board is identical to existing powered drywall sanders and is similar to existing manual sanding devices. Before use the sanding head 30 must have sand paper attached to in a sufficiently fine grit. The rechargeable electric power source 50 must also contain sufficient electrical charge to rotate electric motor 21. By depressing actuator switch 42 and grasping handle 40 in one hand and pole 11 in the other one can guide the position of the sanding head 30 on the drywall joint surface to smooth the joint.

Advantages

From the above descriptions a number of advantages of some embodiments of my cordless drywall sander.

-   -   a) The primary advantage of the cordless drywall sander is the         cordless freedom of movement. This freedom of movement         translates into a more professional finish of the drywall         compound. Larger and more unwieldy machines have in the past         been too cumbersome for finer detail work.     -   b) Use of a square sanding head as opposed to the standard         circular sanding head will allow the cordless drywall sander to         reach into corners where other machines cannot go.     -   c) Being cordless also means a safer tool as there is no longer         an electrical power cord which can become a tripping hazard.     -   d) By making the unit lighter than previous powered sanders the         cordless drywall sander can be used on ceilings for longer         periods without a break. This will help to reduce strain         injuries.     -   e) Versus the manual pole sander, the cordless drywall sander         has the advantage that it reduces the effort of sanding         considerably and will result in a reduction in the amount of         time that it takes to complete sanding.

Conclusion, Ramifications, and Scope

Accordingly the reader will see that the cordless drywall sander can be used safely and efficiently to sand drywall compound with greater efficiency than using previous tools.

-   -   It permits the ability to sand inside corners with it's square         sanding head.     -   It provides ease of use through it's light weight.     -   It prevents injuries caused by tripping over electrical power         cords.     -   It significantly reduces the amount of time it takes to sand         versus manual methods and tools.     -   It provides for use of the tool in locations that do not have         electrical power.

The scope of this sanding tool should not be limited to sanding only drywall. It can be used to sand nearly any surface which requires a long reach without a long electrical power cord. 

1. A cordless drywall sander for causing a working material to act on a subject surface by vibration comprising: (a) an electrical actuator switch; (b) a lightweight extension tube; (c) an eccentrically weighted motor to produce said vibration; (d) a sanding head connected to said handle; (e) a portable rechargeable electric power source used to power said motor.
 2. The tool of claim 1 wherein said extension tube contains the electrical wiring connecting said eccentrically weighted motor, said electrical actuator switch and said portable rechargeable power source.
 3. The tool of claim 1 wherein said sanding head is affixed to said lightweight extension tube.
 4. The tool in claim 1 wherein said portable rechargeable electric power source is affixed to said lightweight extension tube via a handle. 